Cushioning device and method of making the same



May 20, 1958 F. J. SCHOLL 4 2,835,248

CUSHIONING DEVICE AND METHOD OF MAKING THE SAME Filed Jan. 13, 1954 United States Patent CUSHIONIN G DEVICE AND METHOD OF MAKING THE SAME Frank J. Scholl, Chicago, 111., assignor to The Scholl Mfg. Co., Inc., Chicago, 11]., a corporation of New York Application January 13, 1954, Serial No. 403,724

6 Claims. (Cl. 128-80) This invention relates to improvements in a cushioning device and method of making the same, and more particularly to a cushioning device in the form of a surgical pad having a digit loop connected thereto, and which while highly desirable for disposition beneath the ball of a human foot with the digit loop encircling a toe, may also be utilized on the hand with the digit loop encircling a finger, and the device may have other uses and purposes as will be apparent to one skilled in the art.

In the past, many and various types of surgical cushioning pads, particularly those for the treatment or alleviation of afiiictions of the human foot such as callosities on the plantar surface beneath the metatarsal arch, have been developed. While many of these devices were effective in operation, difiiculty has been experienced in the economical manufacture of such devices so that a highly efiicient device might be placed upon the market at a reasonably low cost to the user. This is particularly true in connection with such devices that are not merely flat stampings, but which are made with some care and provided with a digit loop that flatly encircles a digit so as not to have a protruding bulky material to buckle in an awkward or painful manner beneath an article of footwear or the like extending over a toe. In the main, devices of this character heretofore developed and having a flat digit loop were made of separate pieces of material, whereas it is believed to be more economical to make the entire device of one piece of material.

With the foregoing in mind, it is an object of the instant invention to provide a surgical cushioning device having a digit loop provided with a double thickness of material in the cushioning area, and which device is entirely made of one piece of material.

Another object of the invention is the provision of a surgical cushioning device having a digit loop so constructed as to flatly fit around a digit and which device may be made of a single piece of material, even though there may be a double thickness in the cushioning portion of the device.

A further feature of the invention resides in the provision of a surgical cushioning appliance carrying a digit loop, having a double thickness of material in the cushioning part of the device, and which is so constructed as to eliminate any thick abrupt edge contact of the device with the human body.

A further feature of the invention resides in the provision of a surgical cushioning appliance provided with an integral digit loop flatly fitting around a particular digit, and which device may be simply made of a single piece of material, and adapted specifically for a right or left extremity of the body, depending upon the cut of the pattern.

While some of the more salient features, characteristics and advantages of the instant invention have been above pointed out, others will become apparent from the following disclosures, taken in conjunction with the accompanying drawing, in which Figure l is a top plan view of a cushioning device em bodying principles of the instant invention; with a portion of a human foot phantomly illustrated to show a use of the device;

Figure 2 is a plan view of a severed pattern from which the device is formed; and

Figure 3 is a central vertical sectional view through the completed device, taken substantially as indicated by the line ilk-Ill of Fig. 1, looking in the direction of the arrows.

As shown on the drawings:

While it will be clearly understood that the instant invention may be attached to either the hand or the foot of a user, for purposes of clarity it will be herein described in relation to its use on the foot. When the device is positioned upon a foot'as indicated in Fig. 1, where a portion of the foot 1 is illustrated in phantom outline and must be assumed to be on top of the main portion of the device, the cushioning element is disposed beneath the ball of the foot in the region of the metatarsal arch, and thus cases or alleviates callouses, makes walking more comfortable, cushions shock to the wearer particularly if high heel shoes are utilized, and otherwise affords protective aid and relief.

With reference to Fig. 2, the initial pattern from which the device is formed is shown. This pattern may be severed from a large sheet of cushioning material in any suitable manner. Preferably, the material utilized is foam latex, because of its lightness, delicate soft feel when in contact with the skin, resiliency, great restorative power, durability, and the fact that in most cases the cells of the latex structure will be intercommunicative and thus provide some degree of ventilation. It will be understood, however, that other cushioning material such as soft felt and the like, might be used if so desired.

The pattern itself includes a pair of body parts or sheets 2 and 3 connected by a relatively narrow neck-like portion 4. In the illustrated example, the body parts .2 and 3 are generally ovate in contour and it will be noted that the neck-like portion 4 preferably connects with each body part nearer one end thereof than the other so that the device will be specifically made for either a right or left foot. In the illustrated instance, the pattern is made for the formation of a cushioning device for application to a left foot.

Preferably, a cover is provided over the under or outer side of the pattern, and this cover designated at 5 in Fig. 3 may be of any suitable material such as a rubber skin, or a suitable fabric, nylon satin, by way of example, being very satisfactory.

In constructing the cushioning device, the body part 3 is revolved one complete revolution and secured in superposed relationship over the body part 2, by suitable cement 6 (Fig. 3), or in any other satisfactory manner. The revolving of the body part 3 causes the neck-like portion 4 to form a digit loop generally indicated by numeral 7, and it will be noted from the showing in Figs. 1 and 3 that this digit loop is of such a character as to flatly embrace the toe leaving no uncomfortable projection to buckle beneath an article of footwear to the discomfort of the user. Likewise, due to the revolution of the body part 3, the covering material 5 will completely enclose the outer surface of the digit loop 7. The revolving of the body part 3 and its securmenet to the body part 2 is all that is necessary in the making of the device, after the pattern has been cut.

It will be especially noted that the body part .3 is preferably of less size than the body part 2 so that when it is placed upon the body part 2 there is a circumscribing margin of the body part 2 exposed. Further, it will be noted that the outer edge of the body part 3 is preferably serrated, pinked, or otherwise varied from a smooth edge, as indicated at 3, so as to avoid any abrupt edge contact with the foot of the user. Providing the pointed projections around the edge of the body part 3 results in a construction in which the edge portion of the latex foam may flow under pressure, and the contact with the foot of the user is smooth and comfortable.

From the showing particularly in Fig. 3, it will be noted that the finished structure embodies a double thickness cushioning body part which is preferably concavo-convex in shape, with the concavity uppermost to contact the foot of the user.

In use, the digit loop is slipped over a toe, preferably the second toe, and the body portion of the device underlies the plantar surface of the foot in the region of the metatarsal arch. The body portion of the device is maintained in contact with the foot by the hosiery of the wearer or by the disposition of the foot in the shoe, in the event no hosiery is worn, the digit loop preventing the device from slipping out of place. It will be understood, of course, that for a right foot, the digit loop Will project from thebody part of the device near the opposite end of the body part. This makes the device fit smoothly and evenly under the metatarsal arch, with the longitudinal axis of the ovate body part more nearly paralleling the metatarsal arch of the foot.

From the foregoing, it is apparent that I have provided a simply constructed and highly economical form fitting cushioning device for application to the foot or hand of a user, which device embodies a digit loop that flatly encircles the digit, and which device is extremely cornfortable, lends adequate surgical aid to the parts its contacts, and which may be laundered or cleansed whenever desired.

It will be understood that modifications and variations may be effected Without departing from the scope of the novel concepts of the present invention.

I claim'as my invention:

1. In a cushioning device, an integral blank cut from a sheet of cushioning material and comprising a pair of generally oval and non-aligned sections connected by a narrow curvate neck portion, wherein a single revolution rotation of one section to the other and the bonding of the sections in face to face relationship fashions the neck portion into a digit loop for fitting flatly around the digit of a user.

2. In a foot cushioning device, a generally oval shaped body part comprising a "pair of superposed sheets of cushioningmaterial bonded face to face, a narrow neck section integral with and connecting said sheets and forming a toe loop which projects laterally from the body part and is upstanding from the plane thereof, whereby when the loop is engaged over a toe the body part underlies the plantar surface of the foot in the region of the metatarsal arch.

3. In a foot cushioning device, a generally oval shaped body part comprising a pair of superposed sheets of cushioning material bonded face to face, a narrow neck section integral with and connecting said sheets and forming a toe loop which projects laterally from the body part and is upstanding from the plane thereof, whereby when the loop is engaged over a toe the body part underlies the plantar surface of the foot in the region of the metatarsal arch, said neck section emanating from a larger arcuate side edge of each said sheet but nearer one end of each sheet than the other to conform the device to a right or left foot.

4. A cushioning device for application to the body of a user, said device being shaped from an integral substantially flat blank comprising a pair of generally oval body parts connected by a curvature and narrow neck emanating from a larger arcuate edge of each body part, wherein a single complete revolution of one body part relatively to the other and a superposing and securing together of the body parts in face to face relationship fashions, said neck into a digit loop offset laterally and upstanding from a larger arcuate edge of the composite body of the device.

5. The method of making a cushioning device from a blank having two ovate body portions connected together by a neck portion comprising the steps of rotating one body portion with respect to the other by the amount of one revolution, simultaneously laterally translating said one body portion, aligning the body portions in superposed face to face relation, and securing said body portions together.

6. The method of making a cushioning device from a substantially fiat blank having two ovate body portions connected together by a curvate neck portion comprising the steps of rotating one body portion with respect to the other the amount of 360 so that said neck portion fashions a flat digit loop, simultaneously laterally translating said one body portion, aligning the body portions in superposed face to face relation, and securing said body portions together.

References Cited in the file of this patent UNITED STATES PATENTS 281,487 Georges July 17, 1883 1,898,092 McCormick Feb. 21, 1937 2,148,882 Scholl Feb. 28, 1939 2,423,538 Whiteford July 8, 1947 2,633,129 Crawford Mar. 31, 1953 

